Add Double Din Stereo to 2004 Dodge Ram 12-17-2008
Recently I decided to add a double din GPS unit to my 2004 Dodge Ram. This is not normally a hard thing to do but the 2004 Dodge Ram is only made to fit a single din. Follow these steps at your own risk. I assume no responsibility. Do your own research and you know what you will be getting into.
What you will need:
Dremel
Replacement Bezel (not required)
Bondo
Rough to fine sandpaper
Spray paint
Plummer’s Floss
I wont go into the particular unit I installed in the truck or how to wire it because it is pretty easy to figure out. The first thing I suggest, although not required, is to buy a replacement bezel incase you ruin yours. I found one for $50 on ebay. If you ruin yours, you should be able to buy a replacement from the dealer but it will be pricey.
The first step, is to buy your double din stereo and see if it will fit in the area where your stereo goes. I think a 1 and 1/2 din unit will fit with no modification to your truck. If it fits, no modification is necessary to the dash. If however, your double din does not fit, you will have to cut away some excess plastic so it will fit with your Dremel.
As soon as you can snugly fit your stereo in place, you will want to use plummer’s floss or some sort of bracket to mount your unit in place. As soon as you know you can get your unit in the place you want, go ahead and wire it up if you want to. My suggestion would be to buy a $5 wire harness adapter so you don’t have to cut your truck’s factory plug and can easily plug or un-plug your unit.
Now it is time to measure or eyeball if you are me, and cut out space for your unit. I held my plastic bezel over the unit about 10 times cutting and shaving off plastic a little bit at a time making sure not to cut too much with your Dremel. You might want to tape off where you need to cut.
Once you are satisfied you have cut enough plastic or cut too much, it is time to get messy with Bondo. You may have noticed there is some spare space on the left and right side of the unit with the bezel installed. Before moving to the Bondo, I cut away some plastic and used plastic resin to glue them into the sides.
Ok now Bondo. Just get some Bondo at your local Lowe’s or Home Depot and get ready to have some patience. If you have never experienced Bondo before, you must know you have to act quick and it will probably take you many applications to get the shape you want. You may even get to the point where you think you are finished, sand it, and find you have to add more because of a bubble. As long as you mix it correctly, (instructions are on the box) the Bondo will harden really quickly. If you have to add a lot of Bondo to one area and it wont stay in place before hardening, you can tape cardboard in place to hold it.
Once you feel you have the desired shape, time to get sanding. I would first cut away any access Bondo, sand the excess, and make sure it fits. If you don’t like the shape, add more Bondo making sure all dust is gone before applying it. As you can see, this took me many times before I got it where I wanted it. I also could have kept going to perfect it more but I got to a certain point where I was satisfied.
When you are ready for final Sanding I suggest this is where you put your effort. I did not mention this earlier but it is important to make sure your Bondo is dried and hard before sanding. Start with rough paper and move to very fine. My final sanding ended up with a sponge.
Once you have finished sanding, time to paint. At first, I decided to go with a glossy color but my horrible sanding stood out so I decided to go with a flat black. You also may have to paint the whole bezel in case you nicked a part or sanded an un-intended area.
The original Gray I decided to use looked great when painting but from the driver’s seat, some minor imperfections showed up and I went with a flat black which turned out much better. If you want to go with a glossy color, make sure your sanding is good. Finally, the finished product is below (not flat black) I’ll add that picture later.
Tell me what you think.
Greg
****Update 02/15/2010. I decided to paint the whole thing flat black. I found there were much less visual defects you could see with my bad sanding this way.